Insulated water-tight container

ABSTRACT

An insulated container for shipping, transporting, or storing warm or cold items is disclosed, useful for maintaining temperature of items stored or shipped within the container, the container assembly consisting of at least one layer of rigid or semi-rigid material, and at least one layer of flexible, thermally insulating, water-resistant material, in the form of a pouch, which pouch is secured to the rigid material at areas which allow easy reconfiguration of the container to form a finished container having desirable insulating and water-resistant characteristics.

TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates to an insulated container forshipping, transporting, or storing warm or cold items. Moreparticularly, the present invention relates to a new thermally insulatedcontainer assembly, which assembly is water-tight and thermallyprotective of its contents, as well as insulated, so that containercontents may be maintained at constant temperature, while fluids orsolids associated with the contents, if any, may be retained within thecontainer during storage or shipment. The container assembly utilizes alayer of rigid or semi-rigid material, and at least one layer offlexible, thermally insulating, reflective, water-tight material, in theform of a pouch or pocket, fastened to the rigid material in suchfashion as to allow easy and inexpensive manufacture, and compactstorage in a “knock down,” substantially flat, configuration. Whendesired, a user may quickly and conveniently manipulate the knock downassembly to create a volume within the container, thereby forming afinished container having desirable insulating and water-resistantcharacteristics in which the user may keep or store warm or cold itemswith their associated fluids.

BACKGROUND ART OF THE INVENTION

[0002] In many insulated containers, rigid materials are combined withinsulating materials to form containers having insulating properties. Byuse of such containers, product suppliers may ship perishable productsrefrigerated or at room temperature, live or frozen, to customers whilecontrolling the environment in which the perishable products are placed,or while simply extending the useful life of such products before theyspoil. Examples of such uses for containers used in shipping include theshipment of fresh fish, in which a customer has requested that theproduct not be frozen, fresh flowers, around which a cool and moistenvironment should be maintained, and frozen tissues for research. Withall such products, maintenance of constant or low temperature will helppreserve freshness and quality of the products. Maintenance of constantor low temperature will also extend the useful life of the products, andoften thereby increase the distance over which such products may beshipped, as extending the time during which a product is preservedextends the time for shipment during which such product may reach itsdestination. In other insulated containers of this same generaldescription, the usefulness of the container is in preserving thetemperature of foods or beverages used in picnics, family outings, ballgames, and other recreational activities.

[0003] Containers of these types which have been successfully employedfor these purposes include insulated containers made from cardboard andindividual pieces of insulating material, such as Styrofoam or otherlightweight foam type insulation. These types of containers are oftenconstructed by gluing individual pieces of insulating foam material tothe interior surfaces of a cardboard container, which is formed as abox, or by inserting separate foam pieces to insulate each containersurface. While these containers offer advantageous high thermalresistance, cutting and gluing pieces of foam to construct the finishedcontainer requires substantial assembly time, with the result thatcontainers formed in this way are expensive to assemble, and are notwater tight.

[0004] Similar containers include insulated containers made of plasticfoam, typically expanded polystyrene, formed in a mold to the desiredshape. In some cases, additional corrugated pieces may be used toprovide additional structural support. While this type of container alsooffers high thermal resistance and, in addition, ease of assembly, theresulting container is rigidly set in its final form at the time ofmanufacture. As a result, this type of container requires substantialfloor space and volume to store and transport prior to, during, andafter use. Moreover, expanded polystyrene is generally considered tohave a high impact on the environment as undesirable byproducts arereleased upon its manufacture and disposal. In addition, polystyrenedecomposes slowly, and, due to its airy and bulky nature, it occupies alarge volume in land-fill disposal sites.

[0005] Another type of container generally suited for shipment ofperishable products consists of generally rigid walls made of corrugatedcardboard or other suitable material, to which is bonded a flexible,sealable, insulative material having bubbles of gas entrapped therein toprovide thermal insulation. One form of such material is commonlyreferred to as “bubble wrap,” however rubber or plastic foam or othermaterial having the characteristics described herein may be employed inthe present invention. The flexible material may have a reflectivesurface, or an additional layer of flexible reflective material,attached to the rigid walls or flexible, sealable, insulative material,to increase thermally resistant efficiency. While this type of containeris well suited to some applications, and has distinct advantages overother types of insulated containers, the containers of this typeappearing in prior art, with the exception of one disclosed in a priorpatent to this inventor, do not allow for easy assembly by a user, withresulting savings in time and costs. Nor, generally, are such containersin the prior art water-tight for retention of fluids, such as runofffrom melting ice, associated with the products shipped.

[0006] Finally, various apparatus and methods have been used incontainer construction to preserve the contents within the containerfrom breakage or degradation due to mechanical shock experienced whilemoving the container. Such apparatus and methods include utilization ofelastomeric sheets secured to the interior of a hard-case carton,combinations of foam bodies and air sacs placed within the container,and various inflatable mats, tubes, envelopes, and flaps. However, suchapparatus and methods do not exhibit a knock-down, hard-shell, exterior,and a pre-located and secured, interior pouch, thereby simultaneouslyalso exhibiting water-tight, thermally-insulative, and shock-absorbingproperties.

[0007] It may be appreciated, in light of the foregoing discussion, thatthere is a need for an environmentally friendly, affordable, insulatedcontainer, suitable for shipping perishable products, and suitable forproviding convenient temperature control, where the container is easy tomanufacture, thermally resistant, watertight, resistant to mechanicalshock, lightweight, compact prior to assembly, and easy to assemble by auser. The present invention is directed precisely to such usefulcharacteristics.

[0008] A number of schemes have been devised to accomplish one or moreof the goals set forth above. These schemes include single-piece andmulti-part containers of cardboard, foam, and plastic flexible,sealable, insulative material materials. Various designs andconfigurations for such apparatus include:

[0009] U.S. Pat. No. 3,772,712 to Renn et al., which discloses a bag,the lower portion of which is secured within the lower portion of acontainer.

[0010] U.S. Pat. No. 3,952,940 to Malcolm, which discloses a containerfor liquids formed of a paperboard carton and an inner tubular liner offlexible plastic film adhered to portions of the walls of the carton.

[0011] U.S. Pat. No. 3,957,195 to Lin, which discloses a containerassembly composed of a plastic bag and a hollow paper body.

[0012] U.S. Pat. No. 4,030,603 to Angell, which discloses a method forpackaging fragile articles in which such articles are held by heattreat-shrink wrap within a frame and hard container.

[0013] U.S. Pat. No. 4,194,439 to Zimmermann, which discloses a methodfor making a folded lined paperboard container and liquid proof linerhaving an automatic bottom which locks in a set-up position when thecontainer is manipulated from a flat knock-down condition to a set-upposition.

[0014] U.S. Pat. No. 4,235,065 to Freeman, which discloses a method forpackaging fragile-articles in which an expandible tube is layeredbetween such articles, and then filled with gas and closed with a valve,thereby occupying space withing a container.

[0015] U.S. Pat. No. 4,262,801 to Avery, which discloses an apparatushaving flexible and outer container bodies having inflatable chamberswhich hold articles placed there between.

[0016] U.S. Pat. No. 4,284,205 to Hirata, which discloses a pouchinserted in a cylindrical-shell to create a foldable cup.

[0017] U.S. Pat. No. 4,573,202 to Lee, which discloses an apparatushaving an outer shell and an inner inflatable envelope.

[0018] U.S. Pat. No. 4,660,737 to Green et al., which discloses apackaging container formed of a flexible pouch inserted in a closelyform-fitting relationship with an outer rigid carton.

[0019] U.S. Pat. No. 4,854,474 to Murray et al., which discloses acollapsible, self-standing, liquid-tight drinking cup formed of aplastic film liner secured to the inner surfaces of foldablyinterconnected paper-board panels.

[0020] U.S. Pat. No. 4,889,252 to Rockom et al., which discloses aninsulated container formed of corrugated paperboard and a layer offlexible material having air bubbles and foil.

[0021] U.S. Pat. No. 5,009,326 to Reaves et al., which discloses aninsulated multi-part container of corrugated cardboard, folded andstapled to form an enclosure, with one-piece insulated liner.

[0022] U.S. Pat. No. 5,638,978 to Cadiente, which discloses an insulatedwaterproof container for the shipment of produce.

[0023] U.S. Pat. No. 6,296,134 to Cardinale, which discloses aninsulated water-tight container consisting of at least one layer ofrigid or semi-rigid material, and at least one layer of flexible,thermally insulating, water-resistant material, in the form of a pouchsecured to the rigid material.

[0024] In the above-noted inventions, and in other prior art, cardboard,when formed into a box, is a popular material in the shipping industrybecause it is inexpensive and relatively light weight when compared toits strength. As a result, insulated containers composed in part ofcardboard or paperboard help minimize shipping costs. However, cardboardalone is not suitable in those applications in which temperature shouldbe maintained within the container, and it is not suitable in thoseapplications where the contents of the container is a fluid, such aswater, or where fluid is important to preserving the contents. Priorefforts at achieving a suitable container for such purposes havetherefore focused on configurations and materials which have desirablecharacteristics when used in combination with cardboard, or which haveboth rigidity and such characteristics when used without cardboard.

[0025] As a result, various inventions of the prior art, such as thoseof the above-noted patents, employ combinations of various insulatingmaterials, whether rigid or flexible, and water-tight or water-resistantlayers or barriers. A variety of insulating and water-resistant effectsmay be achieved where these materials are combined and formed asdirected by prior art. Thus, good insulative properties are achieved bycontainers utilizing preformed foam, however preformed foam does notallow compact storage, while foam sheets require expensive assembly andcannot achieve water-tightness. In the alternative, cardboard withflexible plastic bubble sheets may be easy to manufacture, however mostsuch arrangements are not water-tight, or are time consuming for a userto assemble if stored and shipped in compact, “knock down” form. Inaddition, the construction of such arrangements are somewhat expensivebecause multiple sheets are required.

[0026] The present invention is directed to combining these desirablefeatures to achieve an insulated container suitable for shipment orstorage of a wide variety of products in the same container, notablyperishable products. Accordingly, a single, low-cost container, may beutilized for wide variety of purposes, and at the same time have thosecharacteristics which make the container widely available, quicklyassembled, and easily employed. While the devices disclosed in priorpatents fulfill their respective objectives, prior patents andinventions do not describe or suggest an insulated, water-tight shippingcontainer, easy and inexpensive to manufacture, compact in storage andshipment, and quickly reformed by a user to produce the final containerhaving the desirable characteristics mentioned herein.

DISCLOSURE OF INVENTION SUMMARY OF THE INVENTION

[0027] An insulated container utilizing corrugated cardboard orpaperboard to achieve structural rigidity consists in its simplest formof the cardboard, an insulating material, and perhaps a means forresisting the transmission of fluids or vapors through the cardboard.The insulating material is typically fastened to the cardboard, orsimply placed within the cardboard carton after the cardboard is formedinto an open box. The means for containing fluids or vapors, if present,may be placed inside the insulating material, or between the insulatingmaterial and the cardboard. Padding or Styrofoam “peanuts” are oftenalso used to cushion the contents of the container against mechanicalshock, and such protective systems may be employed with insulating andwater-resistant materials in appropriate applications.

[0028] The present invention provides a new assembly, easy andinexpensive to manufacture, and compact in its folded “knock down”configuration, in which configuration the assembly may be stored orshipped while occupying a minimum of space. The present invention is anassembly easy for a user to quickly reconfigure into a insulated andwater-tight container, which container is suitable for storing orshipping products requiring a controlled temperature, and whichcontainer may also hold fluids and vapor found with the other contentsof the container.

[0029] In one preferred embodiment of the present invention, aninsulated container assembly is comprised of a rigid or semi-rigid outercontainer or box, and a one-piece insulated liner in the form of a bagor pouch. The outer container may be composed of corrugated cardboard,paperboard, plastic, or other material having sufficient structuralrigidity and strength to satisfy the application at hand. Accordingly,corrugated cardboard is the likely material of choice for an insulatedcontainer designed to ship cut flowers, and for many other applications,while colored plastic might be more suitable to, and therefore chosenfor, a picnic basket or sporting event beverage cooler application.

[0030] The outer container generally will include four sidewalls, a topand a bottom, or flaps which form a top and a bottom when folded overthe opening at the end of the container formed by the four sidewalls.The top or flaps are generally appended to the rigid or semi-rigidsidewalls of the container or, preferably, formed integrally with suchside walls in a single die-cut “blank.” If the container is formed insuch a single blank, the blank is then folded along preset fold lines toform the sidewalls, and at least two opposing edges of the blank aresecured to one another with adhesive to form a tubular section ofsidewalls, with closure flaps extending from each end of the tubularsection. The top and bottom flaps may consist of a single flap at eachside of the blank, or more than one flap at each side of the blank, sothat one or more flaps are available for closure at the end of thetubular section when the sidewalls and tubular section are formed fromthe blank upon its folding. In the alternative, the blank may be cutwithout end flaps at one end, and separate top lid closure separatelycut and supplied to the user along with the side wall tubular section.The bottom flap or flaps (depending on the number of flaps utilized toclose the bottom end of the tubular section) are affixed so as to formpart of the bottom closure. Thus, for instance, where a single flap isused to bridge the bottom opening of the tubular section, an area alongits edge is attached to the opposing side of the tubular section. Wheretwo flaps are used to bridge the bottom opening, the flaps are attachedto each other. In each case, at least two additional flaps affixed toadjacent sides of the tubular section are desirable to complete theclosure at the bottom of the tubular section.

[0031] The general nature of the invention being thus explained, it maybe appreciated that confusion may arise in terminology as the details ofthe blank are described, along with the method of construction resultingin a finished container ready for use. To avoid such confusion, thefollowing terminology will be used:

[0032] The four portions of the die-cut blank which may be bounded ontheir sides by fold or score lines (or an edge of the blank) when theblank is in lay flat form, which portions bear flaps and may be foldedto create a tubular form, will be referred to as “side panels.” The samefour portions of the blank when folded, whether before or afterexpansion of the container, will be referred to as “sidewalls.” Theexception to this terminology is with reference to two of the opposingside panels among these four side panels, which opposing side panels areintended to bend to allow the container to expand and collapse when inuse, and so have, as set forth more fully below, additional fold orscore lines. These opposing side panels may also be referred to as“folding side panels” and the corresponding sidewalls in the expandedcontainer may also be referred to as “folding sidewalls.” The remainingtwo side panels, also opposing one another, but intended to move towardand away from one another during the process of expanding or collapsingthe container, may also be referred to as “non-folding side panels,” andthe corresponding sidewalls in the expanded container may also bereferred to as “non-folding sidewalls.”

[0033] The edges of the side panels having appended top flaps, whichedges form a single line when the blank is in lay flat form, will bereferred to as the “top” edges of the side panels, and the single lineof such side panel top edges the “top” of the blank. Such top edges willalso define the “top” of the container when the blank is folded and thecontainer expanded and ready for use; the top flaps comprise additionalmaterial appended to the top edges of the side panels. The edges of theside panels having appended bottom flaps, which edges form a single linewhen the blank is in lay flat form, will be referred to as the “bottom”edges of the side panels, and the single line of such side panel bottomedges the “bottom” of the blank. Such bottom edges will also define the“bottom” of the container when the blank is folded and the containerexpanded and ready for use; the bottom flaps comprise additionalmaterial appended to bottom edges of the side panels.

[0034] When the blank is in lay flat form, each side panel will have a“width” measured parallel to the top of the blank, such widths beingequal to the distance between the fold or score lines between panels (orbetween a fold or score line and an end of the blank). The width of eachtop or bottom flap appended to each side panel will be measuredconsistently, i.e., parallel to the top of the blank. When the blank isin lay flat form, each side panel will have a “height” measuredperpendicular to the top of the blank, such heights being equal to thedistance between the fold or score lines drawn between each side paneland its appended top and bottom flaps. The distance each flap extendsfrom the side panel or sidewall to which it is appended will be the“length” of such flaps, and the distal edge of each flap shall be its“end.”

[0035] As a result of the above terminology, when the side panels arefolded and the container constructed according to the present invention,the widths of two side panels of the blank will equal the length of thesidewalls of the finished container, while the widths of the remaining(alternate) two side panels of the blank will equal the width of thesidewalls of the finished container. It may be appreciated, however,that if all such sidewall widths are not equal, the width of twoopposing sidewalls may correspond to the overall length of the expandedcontainer. As a further result of this terminology, when the side panelsare folded and the container constructed according to the presentinvention, the height of all side panels of the blank will equal theheight of the sidewalls of the finished container.

[0036] Continuing, the blank which will form the outer container of thepresent invention, prior to folding, may be cut so that all side panelsare of equal width, thereby creating a square when the expandedcontainer is viewed from above (i.e., a square “footprint” for theexpanded container). However, a more usual configuration for thesidewalls of the expanded container results when the blank is cut so asto form two wider side panels and two narrower side panels (all sidepanels remaining equal in height), thereby creating a rectangle when theexpanded container is viewed from above (i.e., a rectangular “footprint”for the expanded container). As noted above, two of the side panels,those corresponding to the folding sidewalls, will generally havescores, or fold lines, extending the height of such side panels. Thefolding side panels will comprise at least alternate panels in thedie-cut blank. Accordingly, such folding side panels will also beopposing sidewalls of the container in its expanded configuration. Thescores or fold lines of the folding sidewalls generally extend fromapproximately the midpoint of the top of each folding side panel, toapproximately the midpoint of the bottom of the corresponding foldingside panel. While these folding side panels may be folded by a userwithout fold or score lines, the score or fold lines of the folding sidepanels allows the folding side panels to be easily folded top to bottom,approximately in half, during manufacture, and the corresponding foldingsidewalls to be easily folded in the same way again after manufacture toexpand or collapse the container during use. Such folding results inmovement of the non-folding sidewalls toward each other, therebycollapsing the container to its knock-down configuration. In containershaving wider and narrower sidewalls, in a preferred embodiment, thescores and fold lines of the folding side panels are preferably formedin the narrower side panels. However, the present invention also workswell when the wider side panels bear scores or fold lines, and thepresent invention specifically includes such a configuration.

[0037] The bottom of the outer container of the present invention (inits expanded configuration) will, as noted above, usually comprisebottom flaps. The bottom flaps appended to the side panels are generallycut to correspond approximately in width to the width of such sidepanels. However, at least one such flap is also generally cutsufficiently long to meet or overlap the end of the corresponding flapappended to the opposing sidewall. That is, when the tubular section ofside panels is manipulated into its open, volume creating configuration,the flaps appended to two of the opposing sidewalls meet or overlap oneanother at their distal ends when such flaps are folded toward oneanother. An area of overlap for two such bottom flaps is important tothe operation of some embodiments of the present invention, as suchoverlap provides an area to apply adhesive or other fastening means sothat the bottom flaps may be affixed to one another (along their area ofoverlap). This area of overlap is generally provided by forming thebottom flaps of approximately equal length, with the exception of onesuch bottom flap which is formed longer, its distal edge therebyextending further from the sidewall to which it is appended. However,other means for providing an area of overlap for two bottom flaps areeasily envisioned, and within the scope of the present invention, as areother attachment means for bottom flaps when such flaps do not overlap.

[0038] When the bottom flaps are affixed to one another, one of theflaps may then be folded against or along the edge of the other flap,thereby allowing the opposing, non-folding sidewalls to which the flapsare affixed to approach each other. In this way the outer container maybe collapsed to a knock-down configuration or, by reversing the movementof the opposing sidewalls, expanded to its open configuration, ready toreceive articles within the volume created thereby. While the sameflexibility between configurations may be achieved with a single flapappended to a bottom edge of one sidewall and extending to the bottomedge of the opposing sidewall (and affixed to an area adjacent to suchedge, the flap being folded approximately in half during collapse), thepreferred embodiments utilize two flaps as set forth herein.

[0039] The remaining flaps of the closure at the bottom of thecontainer, that is, the bottom flaps appended to the remaining foldingsidewalls, may be cut long or short. However, whether long or short,such flaps also bear scores or fold lines extending substantially theirlength, from approximately the midpoint of their line of intersectionwith a sidewalls to approximately the midpoint of their distal edge.Such fold or score lines extend the fold or score lines impressed intothe opposing folding sidewalls, thereby allowing these bottom flaps tobend, easily following the movement of the corresponding foldingsidewalls as these sidewalls are bent or straightened during manufactureor use.

[0040] It may be appreciated that, once the ends of the blank areaffixed to one another to form the tubular section, the above system of(i) folding along the length of the two opposing folding sidewalls and(ii) folding at least one bottom flap appended to the non-foldingsidewalls, allows the container of the present invention to be collapsedaround its “perimeter” (i.e. from folding sidewall to folded bottom flapto opposing sidewall) to its knock-down configuration. By simplyreversing such folding, thereby straightening both the folding sidewallsand the bottom flaps, a user may expand the container to its fullvolume.

[0041] The top of the container may then be closed by the top flaps, orby separate closure ususal in the industry, and sealed. In one suchclosure and sealing arrangement, the top may consist of four top flaps,two of which bear cutouts for insertion of the ends or corners of theother two top flaps, which top flaps may be scored for easy bending orfolding. The top of the outer container, or the top flaps, may, inaddition, feature a handle, or be capable of being formed into a handle,for ease of carrying the finished insulated container, or the outercontainer may carry, separately from the top or flaps, a handle attachedto its exterior. It may also be noted that the folding sidewalls may befolded “outwardly,” so that the fold extends from the body of the(knocked down) container, or the narrow sidewalls may be folded“inwardly,” so that the fold extends within the body of the container inits knock down configuration.

[0042] The one-piece insulated liner of the present invention may beformed from one or more sheets of flexible, thermally insulative,waterproof and air tight material (the “pouch material”), or the linermay be formed from separate sheets having only one of these propertieseach. In its simplest form, the material utilized to form the liner needonly be air tight, so that the liner, once formed from such materialinto a pouch as set forth below, may be water-tight when sealed at itstop. Generally, however, both thermal insulation and waterproofing maybe most simply accomplished in a single sheet utilizing recentlyavailable and inexpensive materials. One material of choice usingcurrently available materials is a flexible plastic layer having atleast one layer of air bubbles entrapped therein (sometimes commonlyknown as “bubble wrap”) laminated to a layer of metalized polyester orfoil.

[0043] This pouch material may be formed in a variety of ways, but iscommonly formed by bonding a first layer of smooth plastic to a secondlayer of plastic having a surface with regularly spaced depressionspushed into it. Upon bonding, the first and second layer adhere in areasin which depressions are not formed, while remaining separated layers atthe areas of the depressions. The result of such bonding is entrapmentof air in the areas of the second layer in which the depressions wereformed. Alternate means for constructing pouch material incorporatebaffles between successive layers, which baffles comprise plastic“walls” between layers. The result of such construction is a materialhaving at least two layers, where the layers do not themselves contactone another, but only contact the walls extending between the layers.The insulative characteristics of such a layered construction areenhanced.

[0044] A pouch material having further enhanced thermal resistancecharacteristics may be obtained by constructing these materials in thepresence of an inert gas, or other gas having a lower heat transmissionrate than air. In such case, the bonded layers of the pouch materialthereafter holds the gas selected within the walls of the liner.Regardless of the gas or gas mixture utilized, a third layer of plasticis often bonded to the second layer of plastic in a fashion similar tothat set forth above, thereby further entrapping gas or gases betweenthe second and third plastic sheets. Further plastic sheets, creatingmore gas bubbles, may be added in this way to increase thermalresistivity. The multiple sheets after such fabrication together createa single, multi-layer sheet of pouch material. One or more of theindividual sheets of plastic comprising the pouch material may becomposed of a plastic having reflective properties, to thereby reduceheat transfer by radiation. In the alternative, another layer ofreflective plastic or other material may be attached to the pouchmaterial, or separately used with the pouch material to reduce heat lossby radiation.

[0045] Other configurations are possible based on similar water-tightand thermally insulative materials, such as those developed by BerkeleyLabs. Using such alternative materials, a gas may be injected into thewalls of the pouch through an open valve, and held within the liner bythe airtight material and the valve upon its closing. Alternatively, aportion of the pouch material may be composed of permeable elastomericmaterial, and the space within the walls of the liner injected with asmall amount of gas other than air, oxygen or nitrogen. Such other gasmay be selected from among a wide variety of gasses which have lowerdiffusion rate across the permeable material than air, gasses such ascarbon dioxide. Finally, its is also possible to construct the presentinvention utilizing multilayer plastic material wherein the layers,while holding a gas as in the preferred embodiment, are connected onlyat their edges. In such way, an inflatable pouch may be created whichexpands to surround and protects fragile materials after the pouch hasbeen inflated.

[0046] In one preferred embodiment of the present invention, a singlesheet of pouch material is simply cut into a rectangular shape, foldedover once, and the cut edges matched. Some edges of the pouch materialare then sealed, leaving unsealed those edges most distant from the foldline, thereby forming a pouch, with top opening away from the fold line,and base of the pocket at the fold line. Alternatively, a single sheetmay be folded over after being cut, and sealed along a side adjacent to,and along a side opposite to, the fold line.

[0047] A variety of means may be utilized to seal the pouch material,however the sealing of edges to create a pouch may be quite easilyaccomplished in one preferred embodiment by the application of heat tothe areas to be sealed as such areas are pressed together. Thecombination of heat and pressure causes the flexible plastic material tomelt slightly, deflating bubbles incorporated into the material, andbonding together successive layers of plastic. Alternate means forsealing the edges to form a pouch include gluing, folding and sewing, orother means calculated to form a water-tight seal. The cutting andsealing as described results in water-tight and insulative pocket, whichmay remain flat as originally folded and sealed or expanded to allow theinsertion of cargo.

[0048] The plastic pouch material is cut to a width which, when sofolded and sealed, will fit conveniently within the sidewalls of theouter container when the outer container is flattened into its knockdown configuration. As so sized, the pouch material will also fitconveniently within the sidewalls of the outer container when it isexpanded to its final three dimensional shape, and may follow the sidewalls in such expansion if attached to them. The pouch material is alsocut to a length which, when so folded, sealed, and placed within theouter container, will extend through the outer container when it isflattened, and out the top and bottom of the flattened container(excluding flaps). When so placed within the outer container, the baseof the pocket of insulating material, at the fold line, extends belowthe bottom edges of the sidewalls of the outer container, while theopening of the pocket, away from the fold line, may extend past the topedges of the sidewalls of the outer container to allow ample material tooverlap or join the top edges of the pouch material to seal the pouchafter expanding and filling the container.

[0049] One variation on the construction of the pouch within the scopeof the present invention includes the forming of cuts in the pouchmaterial extending from the top edge of the pouch a distanceapproximately equal to the length the pouch extends above the top of thesidewalls when the pouch is properly placed on the blank. Such cuts maybe utilized to allow fastening of the material on either side of thecuts to the top end flaps, and so easy closure of the pouch when the topflaps are folded to closure. Another variation on the construction ofthe pouch within the scope of the present invention includes using pouchmaterial which is inflatable after manufacture of the pouch. Such pouchmaterial may be formed into a pouch and placed uninflated on the blank,and fastened to it, prior to constructing the tubular arrangement of thepresent invention. Once the tubular arrangement is formed and the bottomflaps fastened to each other or to the opposing wall as set forth below,the completed container may be shipped in its lay flat configuration,and the user may inflate the insulative pouch after the container isexpanded to its usable configuration. The inflatable pouch meeting thesecharacteristics must be specially designed with areas at each cornerwhere the pouch cannot be inflated, such areas then remaining uninflatedduring later expansion. Such corner areas are necessary to effectiveoperation of a pouch which may be later inflated by a user, as only bynot inflating corners can a pouch of this type fit and expand correctlyinto a hard container. It may be noted that pouch material having thisdescription is available, as is at least one finished pouch having thedesired characteristics.

[0050] In one preferred embodiment of the present invention, thedistance the base of the pocket of insulating material extends from thesidewalls of the container is approximately equal to or greater than onehalf the width of the narrowest sidewall. As a result, the pocket may bedrawn open to form a square or rectangle when viewed from either top orbottom, and the dimension of the resultant square or rectangle allowsthe pocket of insulating materials to approximately cover the areaoccupied by the outer container in its expanded configuration whenviewed from the top or the bottom. The distance the opening of thepocket of insulating material extends from the top flap fold line of thecontainer is also generally equal to or greater than one half the widthof the narrowest side wall. As a result, the top of the pocket hassufficient material to cover the area occupied by the bottom of theouter container, when viewed from the top or the bottom, in its expandedconfiguration. The top of the pocket also generally has sufficientmaterial to allow sealing of the top of the pocket, even in its expandedconfiguration, when the opening of the pocket of insulating materialextends from the top of the container a distance greater than one halfthe width of the narrowest side wall.

[0051] A means for attaching the pouch to the blank, or to the interiorof the tubular section of the outer container, is generally utilized inthe present invention, generally in the form of an adhesive. Theattachment means, when used, is located on both sides of the pouch inone preferred embodiment, along lines at a distance from the edges ofthe pouch of just over one-half the width of the folding sidewalls ofthe container. When the pouch is properly placed on the blank duringconstruction, the adhesive may be applied to the pouch along such lineson the pouch, or along the areas of the non-folding side panels neartheir edges (i.e., near the “corners” of the outer container once theside panels are folded and the container expanded), or along each ofthese areas. These are the primary areas for attachment between thepocket and the outer container. In one embodiment of the present theinvention the pocket must be attached in this fashion, at or near bothside edges, to all four corners of the outer container (when expanded),near the fold lines at the intersection of the sidewalls. The attachmentbetween the pocket and sidewalls is accomplished preferably by adhesiveplaced between the material of the pocket and the area adjacent theedges of the wider sidewalls, however the means for attachment of theinsulating material to the corners of the outer container may be glue,tape, a combination of glue and separable tape of the “velcro” type, orby any other means which does not pierce the pouch material, or causeunequal strain at any point in the material. Methods of attachment whichallow for removal of the insulated pocket from the outer container havethe additional advantage of allowing cleaning of the pocket afterseparation from the cardboard, thereby preserving the structuralintegrity of the cardboard against weakening by contact with water, andrecycling the outer container and insulative pocket separately.

[0052] It should be specifically noted here that, while the adhesive orother attachment means set forth above assists in maintaining the pouchin its proper position within the outer container, and assists expansionof the pouch when the outer container is expanded, attachment means isnot necessary to all embodiments of the present invention. In someembodiments the pouch may simply reside within the tubular section ofthe outer container during shipment, and the pouch will expand withinthe outer container during use, both by action of the sidewalls againstthe pouch, and by action of the contents of the pouch as such contentsrequire volume within the pouch when placed within it.

[0053] Once the tubular assembly with folded bottom and attached pouchare constructed according to the apparatus set forth herein, a userwishing to employ the present invention may, as noted more fully belowin relation to the method of the present invention, simply grasp thetubular assembly, manipulate it to expand the assembly by moving thenon-folding side panels apart, and lock the assembly in its expandedconfiguration by locking the folding side panel bottom flaps into thenon-folding side panel flaps, by taping or gluing the bottom flaps toeach other or to the side walls of the now expanded container, or byother appropriate means. In its expanded configuration, the assembly ofthe present invention is open to accept articles for shipment orcarrying, closed at the bottom, capable of closure at the top by meansof top flaps and excess material at the top of the pocket, and, once soclosed, a container having an exterior hard shell, and a water-tightinterior pouch resistant to transfer of heat into or out of thecontainer.

[0054] The manufacture of the present invention involves a series ofsteps, beginning with the cutting of a blank for the tubular assemblyfrom a rigid or semi-rigid material. In such manufacture, a measure ofsuch material sufficient to create the finished product is cut to createa flat blank having the requisite side panels and flaps. The blank maybe scored or pressed along appropriate lines during cutting to createthe scores or fold lines of the blank of the present invention, or suchscoring or pressing may take place before or after such cutting of theblank. A measure of insulative and water-tight material sufficient insize to create a pocket or pouch of appropriate size is also cut,folded, and sealed along at least two sides (leaving open at least oneside). The pocket is, once formed, placed at the correct position on theblank, or upon adhesive residing on the blank, or adhesive is applied tothe pocket and then the pocket is placed at the correct position uponthe blank. The blank is then folded over the pocket and the edges at theends of the blank affixed to one another by additional adhesive or othersuitable means. Finally, the distal edge of at least one flap of thenon-folding side panels is folded over the edge of the opposingnon-folding side panel, or over the distal edge of the opposing flap ofthe opposing non-folding side panel, and fastened in such position tocreate a folded bottom for the container. In the alternative, adhesivemay be applied to the correct positions on the pocket, or the interiorof the tubular section once formed, and the pocket then placed in thecorrect position within the tubular section, and the tubular sectionthen collapsed to its knock-down configuration. While these methods ofconstruction are stated somewhat generally to provide guidance on theoverall process, the preferred method proceeds more specifically asfollows:

[0055] Starting with a measure of rigid or semi-rigid material, a blankis cut in a shape which, in one embodiment of the present invention, hasmaterial sufficient to form four side panels for creating the sidewallsof the present container once constructed, at least one bottom flap atone side of the blank for forming a closure at the bottom of thecontainer once constructed, and at least one top flap at the other sideof the blank for forming a closure at the tope of the container onceconstructed. The bottom flaps are formed of unequal length in onepreferred embodiment, the longer bottom flap appended to a non-foldingside panel residing between two folding side panels. The blank is alsocut to form an end tab at one end of the blank in one preferredembodiment, the end tab usable for affixing one end of the blank to theother end of the blank using adhesive or other suitable means, therebycreating the tubular construction of the container. Before the blank iscut, or in the blank itself as or after it is formed, a number of foldlines or score lines are impressed in the material of the blank, whichfold lines define the four side panels, the top flap or flaps, thebottom flaps or flaps, and the end tab. These fold or score lines allowthe blank to bend easily between the side panels to create the foursidewalls, to create the top and bottom flaps for closure, and to createthe end tab for forming the tubular assembly when the end tab is affixedto the area near the edge of the opposing end of the blank. Twoadditional fold or score lines are impressed the length of each foldingside panel, along the mid line of each such panel. An additional fold orscore line is, in one embodiment of the present invention, impressedalong a line near the distal edge of the longer bottom flap, for easybending of that bottom flap once the tubular assembly is formed, and thebottom flaps affixed to one another using attachment means as set forthbelow.

[0056] Starting again with a measure of flexible, thermally insulative,waterproof and air tight “pouch material,” in one preferred embodiment asheet of such material is cut in the proper shape and size to “fit” theblank. More specifically, the sheet is generally cut in a rectangularshape with a width such that, if the sheet is centered on a non-foldingside panel of the rigid blank, the sheet will extend beyond the sideedges of that side panel (i.e., beyond the fold or score lines betweenside panels) a distance of about one-half the width of the folding sidepanels. The sheet of pouch material is also cut with a length such that,if the sheet is centered on a non-folding side panel of the blank, thesheet, if folded in half, will also extend beyond the bottom edge ofthat side panel (i.e., beyond the fold or score line between that sidepanel and the bottom flaps) a distance of about one-half the width ofthe folding side panels, and beyond the top edge of that panel (i.e.,beyond the fold or score line between that non-folding side panel andthe top flap or flaps) a distance of at least one-half the width of thefolding side panels.

[0057] Once cut, the measure of pouch material is generally folded inhalf upon itself, the edges and ends matched, and the material sealedalong its two side edges. Such sealing creates a pouch or pocket in layflat form comprised of two sides of flexible pouch material, a fold linebetween the sides of the pouch at its bottom, two sealed side edges, theside edges often showing seal or melt lines where the material is sealedto itself along the edges, and one open end at the unsealed edges acrossfrom the fold line. While somewhat less convenient and more bulky, thepouch may also be formed from two separate pieces which together havedimensions approximately equal to the single measure noted above. Suchseparate pieces may be joined along three edges to create the lay flatpouch with one open end required by the present invention.

[0058] Whether formed of a single piece in the preferred embodiment orfrom two separate pieces, the corners of the pocket adjacent the foldline of the pocket, once formed, may be cut to reduce bulk, and thenresealed to regain water-tight and thermal properties. The angle andamount of such cut corner cutting may vary, however the preferred angleof cut is about 45 degrees, and the preferred distance of such cut fromthe corner of the pouch prior to cutting should be a distance of aboutone-half the width of the folding side panels of the rigid cut blank.While the corners of the pouch may be cut to reduce bulk in someapplications, the preferred embodiment is to leave the corners, whichmay be easily folded into the container or under the flaps at the bottomof the container during expansion. The material of the corners may alsobe simply kept together by melting it near the line where the cornersmight be cut in some embodiments, or melting all the material of thecorners of the pouch.

[0059] Returning to the flat blank cut from rigid or semi-rigidmaterial, a means for attaching the end of the blank or, in thepreferred embodiment, end tab (or tabs) of the blank, is secured to theend of the blank or end tab. As a result, the end tab may be affixed bysuch attachment means to the area near the edge of the opposing end ofthe blank, to thereby create a tubular shape from the blank. In asimilar way, means for attaching the bottom flaps to one another issecured to at least one bottom flap, near its distal edge. As a result,one bottom flap may be affixed by such attachment means to the opposing,non-folding side panel or, in a preferred embodiment, to the opposingbottom flap. Other attachment means may be secured to both non-foldingside panels at least along the areas close to the edges of such sidepanels. While the areas to which attachment means, when used, aresecured may be fairly narrow, a wider placement of such attachment meansresults in a fuller connection between the pocket and the blank, andultimately a smoother interior compartment within the pocket once thecontainer is opened to its expanded configuration. In addition, theadhesive or other means of attachment of the pouch to the blank, whenused, may be such as to allow removal of the pouch from the containerfor separate disposal or recycling of the pouch and outer container, orthe means for attachment in some applications may be durable to keep thepouch securely within the outer container.

[0060] Of course, the steps in the process of the present invention maybe reversed in that the attachment means secured to the end tab, bottomflaps, and side panels may be secured to the flat blank prior toformation of the pouch as set forth above, or these steps may be takenin any order (as noted below, attachment means may also be applied tothe end tab, bottom flaps, and side panels either before placing thepouch onto the rigid blank or afterwards).

[0061] After the rigid or semi-rigid blank is properly cut, andattachment means secured to at least one end tab and bottom flap as setforth above, and after the pouch or pocket of the present invention hasbeen formed from the pouch material has been formed by cutting, folding,and sealing as set forth above, the pocket may then be joined with theblank, and attached to it using the attachment means secured to theblank. This is accomplished in one preferred embodiment by placing thepocket on the blank, and on the attachment means on the non-folding sidepanels of the blank, so that the pocket is approximately centered oversuch side panel between two folding side panels, such that the sealedside edges of the pocket extend across the fold or score lines betweenthe non-folding side panel and each folding side panel, and furtheracross about one-half the width of each such folding side panel. In suchposition, the edges of the pocket extend approximately up to the fold orscore line running the length of each folding side panel. In itspositioning, the pocket is also placed on the blank as set forth abovein a position such that the bottom of the pocket, at the pocket foldline, extends from the bottom edge of the non-folding side panel andacross most of the length of the longer bottom flap appended to thatside wall (i.e., almost to its distal edge). In such position, thebottom edge of the pocket then extends approximately up to the fold orscore line near the distal edge of the longer bottom flap, a distance ofapproximately one-half the width of the folding side panels. In suchposition, finally, the top edges of the pocket forming its open end alsoextend beyond the top edge of the non-folding side panel, and across thetop flap attached to that panel, a distance of at least one half thewidth of the folding side panels.

[0062] Once in position on the blank, the pocket may be simply pressedinto contact with the attachment means residing along the edges of thenon-folding side panel of the blank, to thereby attach the pocket to theblank near such edges, or attach the pocket to a larger area of thewider side panel of the blank wherever the attachment means has beenapplied to the side panel (as set forth above). In the alternative, thepocket may simply reside in the proper position without attachmentmeans, and the process of construction may continue (as set forthbelow).

[0063] After the pocket is positioned correctly on the blank andattached to the blank using the procedure set forth above, a user maythen easily fold one-half of one folding side panel, at the fold line ofthat panel, over a side edge of the pocket and across the body of thepocket, the user thereby folding the end of the blank over the pocketnear its edge a distance equal to about one-half the width of thefolding side panel. At the other side of the pocket, a user may alsoeasily fold one-half of the other folding side panel, along with theremainder of the blank, at the fold line of the folding side panel,across the other side edge of the pocket and across the body of thepocket. The user thereby folds the other end of the blank over thepocket near its second edge a distance equal to about the width of thewider side panel plus about one-half the width of the narrower sidepanel. Of course, the order of folding of the folding side panels overthe pocket as set forth above may be reversed with the same overallresult.

[0064] When each end of the blank has been folded as set forth above,the ends of the blank, or the end tab at one end of the blank and theother end of the blank in the preferred embodiment, or end tabs at eachend of the blank, may overlap. Since the ends of the blank, or the endtab at the end of the blank, bear attachment means applied previously asset forth above, construction continues when the ends of the blank, orone or more end tabs at the ends of the blank, overlap, by pressing theends of the blank, or such end tab and other end of the blank, together.This brings one end of the blank into contact with the attachment meansresiding along the edge of the other end of the blank, or the end tab,into contact with the attachment means residing along the other end ofthe blank, thereby securely fastening the ends of the blank together tocreate a (flattened) tubular arrangement of both wide and narrow sidepanels (with flaps). Since the pocket of the present invention wasappropriately placed on the blank, and fastened to it via appropriatelyplaced attachment means prior to folding the blank in at least onepreferred embodiment, the tubular arrangement of side panels, oncefolded as set forth above, has within it the previously positionedpocket. Since the pocket of the present invention was placed on onenon-folding side panel of the blank prior to folding the blank, andsince attachment means was appropriately placed on the other non-foldingside panel of the blank prior to folding the blank in at least onepreferred embodiment, both non-folding side panels of the tubulararrangement of side panels, once folded as set forth above, may besecurely attached to the pocket by the attachment means. As a result,the tubular arrangement of side panels after folding has within it, andsecurely attached to it in some preferred embodiments, the previouslyplaced pocket. If attachment means is used, the areas of attachment ofthe pocket to the side panels correspond to the area on the non-foldingside panels to which attachment means was previously applied. It shouldbe noted that the order of steps in applying the attachment means to theappropriate places to secure the pouch to the blank during construction,of attachment means is used, may be reversed. That is, the attachmentmeans may be applied to the end tab, bottom flaps, and side panelseither before placing the pouch onto the rigid blank or afterwards, orin any order, and the attachment means may be applied to either suchareas on the blank, or on corresponding areas of the pouch, or bothprior, to bringing the pouch and blank together.

[0065] After the pocket is positioned correctly on the blank andattached to the blank (in one embodiment) using the procedure set forthabove, and the ends of the blank attached to one another as set forthabove, a user may then easily fold the edge of the longer bottom flap(appended to one of the non-folding side panels), at the fold line atthe distal end of that flap, over the edge of the opposing bottom flap.When the longer bottom flap has been folded as set forth above, thedistal edges of the flaps of the non-folding side panels may overlap.Since the area near one or both distal edges of such bottom flaps bearattachment means applied as set forth above, construction continues whensuch bottom flaps overlap by pressing the areas having such attachmentmeans together. This brings one area of one bottom flap into contactwith the attachment means residing along the area of the opposing bottomflap, thereby securely fasten the distal ends of the bottom flapstogether to create a folded bottom end for the tubular assembly. Ofcourse, the order of folding of the bottom flaps to create the foldedbottom end for the tubular assembly may be reversed without changing theend product, i.e. a tubular assembly, with folded bottom end, andattached pocket within.

[0066] As an alternative to the above procedure, for constructing thecontainer of the present invention, the pocket of insulating materialmay be inserted into the outer container once it has been folded to atubular assembly, with end tab, opposing blank edge, and bottom flapssecured as above. While not as desirable for a number of reasons, such aprocedure may be utilized when a slow set adhesive or other means isused to fasten the pouch to the interior of the tubular section, or whenthe pocket and outer container are to be constructed without attachmentmeans between them. In such procedure, the pouch is again positioned sothat opposite edges at the sides of the pouch extend into the folds ofthe folding sidewalls of the container, with such edges adjacent thefold lines of such sidewalls. Further, the base of the pouch ispositioned so that the fold line at its base extends into the foldedbottom created by the bottom flaps when the container is in its knockdown position. Once the pocket is in position within the sidewalls ofthe container, the pocket is attached to the sidewalls near the edges ofthe corresponding non-folding sidewalls of the outer container as beforein those embodiments utilizing attachment means between pouch and outercontainer.

[0067] As a result of manufacture in the method described herein, thepresent invention, as noted above, may be incorporated into an insulatedcontainer assembly which is capable of being folded flat, with sidewalls of the outside container in the knock down configuration, and withthe flattened flexible, sealable, insulative material of the pocketresiding within the side walls. To utilize the present invention, a usermay select a flattened container of appropriate size, and manipulate theouter container to expand it in the manner set forth herein. Upon suchexpansion, the flexible, sealable, insulating pocket of one version ofthe present invention is pulled along with the (non-folding) side wallsof the outer container, thereby filling the volume created upon itsexpansion. At the top of the box, the opening of the pocket opensnaturally when the outer container is expanded, thereby allowingplacement of articles within the pocket and the outer container. At thebottom of the outer container, the bottom of the pocket is reformed asthe corners of the outer container, at the fold lines between sidewalls, pull the opposing sides of the pocket away from each other. Atthe same time, and in response to such pulling, the sealed edges of thepocket are pulled inward, in one preferred embodiment, toward the mainbody of the pocket.

[0068] The user continues to expand the outer container until it reachesa point at which the sidewalls are perpendicularly oriented to theiradjoining sidewalls, and the bottom or bottom flaps may be manipulatedinto position to close the outer container at its bottom. At the pointof maximum expansion of the outer container, the insulated pocket isreformed so that the pouch material runs substantially all around theinside of the sidewalls, and extends from the top of the container.Meanwhile, as the outer container is opened, the sealed side edges ofthe pouch near the midline of the folding sidewalls of the outsidecontainer are drawn toward the center of the container, as is the foldline of the pouch at the bottom of the container.

[0069] At full expansion of the outer container, the bottom of the outercontainer formed by the joined flaps of the non-folding sidewalls formsa substantially flat surface. The remaining flaps (i.e., the flaps ofthe folding sidewalls) may then be easily folded over the bottom of theouter container, and secured in place by appropriate means. Such foldingover the bottom of the container will also generally result in foldingthe flaps of the folding sidewalls over the exposed bottom corners ofthe inner pouch, which normally project from the interior of the containout between the folding sidewalls and the now straightened flaps of thenon-folding sidewalls. In a rectangular “J lock” bottom box design, thebottom closure is normally accomplished when the flaps of the foldingsidewalls are folded around the bottom of the container after expansion,and folded into and locked into place in slots formed in the flaps ofthe non-folding sidewalls. Closure of the pocket at its top then mayproceed by folding the pocket material, and securing it in place, orotherwise securing the ends of the pocket material to form a closure.Such closure may be accomplished in a variety of ways currently in use,including use of a “lip & tape” (or lip with adhesive, or pressuresensitive tape) design, with or without folding the edges of the openingto achieve tighter closure. In most cases the pouch material, securednear the edges of the pocket opening, are used to close the pocket uponfolding. However, a preferred method of closure in the commercialshipping market is through use of a continuous rotary sealer or heatsealer in which a user may apply, generally by hand, both pressure andheat to melt the edges of the pocket opening together. By such means, auser may create a pocket having water-tight characteristics even if thecontainer as a whole is upended during shipment. Upon completing theclosure of the pocket, the user may close the outer container in the waydictated by the design of the outer container.

[0070] By the above process, the user may store the insulated andwatertight container assembly in its knock down configuration pendinguse, select and quickly manipulate assembly to reconfigure the assemblyto its final expanded shape, and secure the assembly in such finalshape, ready to receive articles. The reconfiguration process is bothquick and convenient for the user, and the resultant containerinexpensive and readily available. Further, by means of the presentinvention, a manufacturer may quickly and inexpensively provide a lightweight, durable, insulated, and water-tight container which may bemanipulated into its final shape by the user, and store and ship suchassembly using a minimum of space and cost.

[0071] The more important features of the invention have thus beenoutlined, rather broadly, so that the detailed description thereof thatfollows may be better understood, and in order that the presentcontribution to the art may be better appreciated. Additional featuresof specific embodiments of the invention will be described below.However, before explaining preferred embodiments of the invention indetail, it may be noted briefly that the present invention substantiallydeparts from pre-existing designs of the prior art, and in so doingprovides the manufacturer and distributer with the highly desirableability to easily and inexpensively manufacture the new assembly in acompact, folded “knock down” configuration, and store or ship theassembly in such configuration while occupying a minimum of space. Thedesign of the present invention has distinct advantages over prior art.Thus, the assembly of the present invention provides an assembly easyfor a user to quickly reconfigure into a insulated and water-tightcontainer, which container is suitable for storing or shipping productssuch as flowers, fruits, beverages, or other products requiring acontrolled temperature. It also allows the insulated containerincorporating the design to hold fluids and vapor within the containerthereby increasing insulative properties of the container, whilepreventing fluids from leaking through the container with resultant messand loss of structural integrity. It also provides a water-tight orwater-resistant liner in a collapsible, structurally rigid exterior, forspace saving storage of thermally sensitive contents and any associatedfluids. Accordingly, this water-tight container design satisfies airlinecargo regulations relating to shipping with water and ice, and meltedice runoff containment. The rigid exterior of the present invention mayitself be manufactured with water resistant adhesives for durability andreusability. Finally, the assembly of the present invention is designedand composed of such materials that it utilizes less material overall inconstruction and, eventually, disposal, without the use ofcloroflorohydrocarbons (CFCs), while the construction of the assemblyallows reuse. Accordingly, the assembly is less environmentallyburdensome.

[0072] These consequences arising by use of the present invention resultin substantial savings in user time, and substantial savings in expensein manufacture and distribution, and reduction in storage area until theuser determines that a container having the characteristics noted hereinare required, at which point the insulated container system of thepresent invention is simply applied to the task at hand.

OBJECTS OF THE INVENTION

[0073] The principal object of the present invention is to provide a newinsulated container assembly for use in transporting temperaturesensitive goods, with the additional characteristic of providing a meansfor retaining fluids and vapors within the container.

[0074] A further object of the present invention is to provide aninsulated container assembly which may be inexpensively and easilymanufactured utilizing standard, readily available materials.

[0075] A further object of the present invention is to provide aninsulated container assembly which may be transported and stored whennot in use in a flattened configuration, thereby preserving space andreducing transportation and storage costs.

[0076] A further object of the present invention is to provide aninsulated container assembly which is quickly and easily expanded by auser from its folded configuration to its configuration when in use.

[0077] A further object of the present invention is to eliminate theneed for voluminous, rigid, three dimensional insulating liners whichmust be carried separately, and placed in position within a containerafter it has been expanded.

[0078] A further object of the present invention is to provide consumerswith a convenient, more environmentally sound option to the disposablecoolers currently constructed of expanded polystyrene foam.

[0079] A further object of the present invention is to provide aninsulated, water-tight container utilizing an interior pouch of standardsize which may be fitted to a rigid outer container of varyingdimensions.

BRIEF DESCRIPTION OF DRAWINGS

[0080] The invention will be better understood and objects other thanthose set forth above will become apparent when consideration is givento the following detailed description thereof. Such description makesreference to the annexed drawings wherein:

[0081]FIG. 1 is a top-side perspective view of a flexible plastic layerhaving at least one layer of air bubbles entrapped therein laminated toa layer of metalized polyester or foil.

[0082]FIG. 2 is a top-side perspective view of the flexible plasticlayer of FIG. 1, in which the layer has been folded once, and the edgesmatched and sealed after folding to create a pouch. In FIG. 2 thecorners of the pouch near the fold line have been cut and resealed toreduce bulk.

[0083]FIG. 3 is a plan view of a rigid or semi-rigid outer container cutblank prior to assembly, and showing preferred areas for application ofadhesive or other attachment means, apparent fold lines, and insertionpoints for joining bottom flaps after expansion.

[0084]FIG. 4 is a top-side perspective view of the rigid outer containerof FIG. 3, upon which the pouch or pocket of the present invention hasbeen place, and affixed in its preferred position by contact of thepouch with the attachment means appearing in the preferred areas of FIG.3.

[0085]FIG. 5 is a top-side perspective view of the rigid outer containerof FIG. 4, in which the side panels of the blank have been folded towardeach other over the pouch, and the end tab at one end of the blank, withits attachment means, placed in contact with the other end of the blankand affixed thereto using the attachment means, thereby creating thetubular arrangement of sidewalls. Prior to completion of construction,FIG. 5 shows the bottom flaps appended to the wider sidewalls in unequalwidth, prior to folding of one bottom flap over the other to create thebottom, and FIG. 5 also shows each narrower sidewall in foldedconfiguration prior to expansion of the container.

[0086]FIG. 6 shows the same top-side perspective view of FIG. 5, stillin knock down configuration, but with one bottom flap of one of thewider sidewalls now affixed to the other bottom flap of the other widersidewall along the area near their distal edges, thereby creating abottom for the container.

[0087]FIG. 7 is a perspective view of the bottom of the rigid outercontainer of FIGS. 5 and 6, in which the outer container and theflexible plastic pouch of the preceding figures have been expanded tocreate a volume into which objects may be placed. When so viewed fromthe bottom, the bottom flaps, which have been affixed to each other neartheir distal edges, have unfolded to create a bottom for the containerwhile the container expands. At the same time the pouch affixed to theinterior of the container sidewalls has also expanded.

[0088]FIG. 8 is a top-side perspective view of a the rigid outercontainer of FIG. 7, wherein the flexible plastic pouch has followed theside walls of the outer container in its expansion, thereby opening theinterior of the pouch to receive objects, with the free top edges of thepouch extending beyond the body of the container to allow closure of thepouch with the material so extending.

[0089]FIG. 9 is a flow chart diagram of the process of manufacturing thepresent invention from rigid or semi-rigid material (to form the blank),and flexible, waterproof, air-tight, and insulated material (to form thepouch or pocket).

DESCRIPTION OF A FIRST PREFERRED EMBODIMENT

[0090] Referring initially to FIG. 1, a flexible plastic layer 5 havingat least one layer of air bubbles entrapped therein laminated to a layerof metalized polyester or foil (sometimes commonly known as “bubblewrap”) is shown. The layer 5 has edges 11 at each end, edges 12 alongeach side of the layer.

[0091] In FIG. 2, the flexible plastic layer 5 of FIG. 1 is shown foldedmidway along fold line 13, end edges 11 have been matched with eachother, and side edges 12 have been matched with themselves. In suchposition, side edges 12 are sealed along their length, generallycreating a seal line 14. Upon sealing, the layer 5 forms a pouch orpocket 10 with an opening 15, two sealed side edges 12, and a fold ofcontinuous material at the central fold line 13. In FIG. 2, the pouch offlexible plastic is may also be cut at its corners 16 near the centralfold line 13 to reduce bulk of the pouch 10 once it is positioned withinthe rigid container sidewalls of the container after expansion. However,in most cases such cuts at corners 16 is not necessary, the excessmaterial being easily folded later between bottom flaps of thecontainer. The angle of cut for the corners 16 appearing in FIG. 2, ifsuch cuts are made, is the preferred angle of about 45 degrees. Theamount of material cut from corners 16, if such cuts are made, is theamount removed when cutting at a 45 degree angle at a distance from thecorner 16 of the pouch 10 of about one-half the width of the narrowerside panels of the outer container. FIG. 2 two shows the cut edges 17where the corners 16 of pouch 10 have been removed, and corner seallines 18 as cut edges 17 have been resealed to retain the water-tightand thermal properties of the pouch 10 prior to cutting corners 16.However, as noted above, the pouch corners may remain uncut in manyapplications with good effect.

[0092] Referring now to FIG. 3, a single piece of rigid or semi-rigidouter container material is shown cut into a blank 20 laying flat priorto its assembly. Top flaps 21, bottom flaps 22, non-folding side panels23, folding side panels 24, and a single end tab 25 are formed from therigid container material by cutting away excess material. At the end ofblank 20 opposite end tab 25, blank mating edge 31 is shown.

[0093] After cutting the container blank, or at the same time as theblank is cut, fold lines 9 are pressed into blank 20 between non-foldingside panels 23 and folding side panels 24, to provide a means for easyfolding of all side panels against one another. As a result of pressingsuch fold or score lines into blank 20, top flaps 21 and bottom flaps 22may be easily folded at top flap fold lines 28 and bottom flap foldlines 29, and all side panels may be easily folded against one another.Additionally, fold or score lines 30 are pressed or scored into foldingside panels 24 of blank 20 midway between non-folding side panels 23, toallow easy folding of narrow side panels in half lengthwise (i.e., topto bottom in the expanded container). Additionally, end tab fold line 6is pressed or scored at the end of blank 20 to allow easy bending of endtab against the body of blank 20. Finally, bottom flap fold line 7 ispressed or scored into bottom flap 22 to allow easy bending along theedge of bottom flap 22, thereby allowing flap area 19 of bottom flap 22to bend for attachment to opposing bottom flap 22, and so allow flexureof bottom flaps one against the other after such attachment so that thecontainer of the present invention may be collapsed or expanded asneeded. Fold line 7 in this preferred embodiment is formed as two foldlines pressed into the blank close together, allowing the volume withinthis fold in the knockdown configuration to vary, thereby allowing thecontainer to easily fit around pouch material of different thickness.

[0094]FIG. 3 also shows first preferred areas 26 as preferred areas forapplication of fastening means, generally adhesive, which willeventually be used to attach the pouch of FIG. 2 to the container blank20. Preferred areas 26 are the most important areas to establish suchattachment, as these preferred areas correspond approximately to adistance from the edges 12 of the pouch 10 of about one-half the widthof the folding side panels 24 of the blank 20. In such position,attachment between non-folding side panels 23 and the pouch will allownon-folding side panels 23 to open the pouch 10 upon expansion of thecontainer prior to use. However, additional adhesive may be applied toother, secondary attachment areas 27, or even over the area of theentire area of the non-folding side panels 23 in some applications ifadditional strength is desired. Adhesive is also applied to attachmentarea 19 for attaching bottom flap 22 to opposing bottom flap 22.

[0095] When constructed as set forth in FIG. 3, a convenient method ofmanufacture of the outer blank 20 is disclosed, so as to make assemblywith pouch 10 possible with minimal expense and effort. In suchassembly, outer blank 20 is first cut as shown in FIG. 3, and adhesive(not shown), or an adhesive strip (not shown), is applied or secured tothe preferred areas 26, after which pouch 10 is set on blank 20 so thatthe pouch rests between folding side panel fold lines 30. In suchposition a mid-line of pouch 10, running from the mid point of opening15 to the mid point of fold line 13, is equidistant from such fold lines30. Pouch 10 is also positioned so that pouch fold line 13 rests at ornear bottom flap fold line 7. In such position the top edges 11 of pouch10 rest near the distal edge of top flap 21. By such placement, pouch 10is placed in contact with the adhesive or adhesive strip of thepreferred areas 26 near the edges of wider panels 23, and is therebysecured to such areas 26. In such position, pouch end edges 11 mayextend beyond top flaps 21, however pouch bottom at fold line 13 shouldnot extend beyond bottom fold line 7 of bottom flap 22.

[0096] After placement of pouch 10 as described above, the ends of blank20 may be folded across pouch 10 in such a way as to position end tab 25over the outside of mating edge 31, and fastening flap 25 may then besecured to mating edge 31 utilizing the same adhesive used to securepouch 10 to preferred areas 26 of blank 20. After placement of pouch 10as described above and folding of ends of blank 20 as described above,the distal edge of flap 22 and the fastening area 19 proximal to thatedge, may be folded across the bottom edge 13 of pouch 10 in such a wayas to position fastening area 19 over the outside of the mating edge 8of opposing bottom flap 22 and fastening area 19 may then be secured tomating edge 8 utilizing the same adhesive used to secure pouch 10 topreferred areas 26 of blank 20. In this way, a single application ofadhesive may be used to secure the pouch 10 to blank 20 at preferredareas 26, to close blank 20 over pouch 10 during assembly to create atubular form, and to seal opposing bottom flaps 22 one to the otheralong bottom flap attachment area 19 to create a flexible bottom for thecontainer of the present invention.

[0097] In FIG. 4, the rigid or semi-rigid blank 20 is shown inperspective view, with pouch 10 placed in position as set forth above.In FIG. 4, pouch 10 rests between folding side panel fold lines 30, withpouch edges 12 on each side of pouch 10 resting near such fold lines 30.In such position a mid-line of pouch 10, running from the mid point ofopening 15 to the mid point of fold line 13, is equidistant from suchfold lines 30. Pouch 10 is also positioned so that pouch fold line 13rests at or near bottom flap fold line 7. In such position the top edges11 of pouch 10 rest near the distal edge of one of top flaps 21. By suchplacement, pouch 10 is placed in contact with the adhesive or adhesivestrip of the preferred areas 26 under pouch 10 (not shown) near theedges of wider panels 23 under pouch 10 (not shown) and is therebysecured to such areas 26. In such position, pouch end edges 11 mayextend beyond top flaps 21, or not, however pouch bottom at fold line 13should not extend beyond bottom fold line 7 of bottom flap 22. End tab25 is shown with its area for adhesive distal to end flap fold line 6,and preferred areas for adhesive 26 on non-folding side panels 23,however in FIG. 4 blank 20 has not yet been folded along fold lines 30,but rather remains in open position.

[0098] In FIG. 5, the rigid or semi-rigid blank 20 is shown in the sameperspective view of FIG. 4, with pouch 10 placed in position as before.However, in FIG. 4, blank 20 has been folded along narrower panel 24fold lines 30, and the ends of blank 20 have been fastened togetherutilizing end tab 25 affixed over and to the area adjacent blank matingedge 31 (not shown) of non-folding side panel 23. By such affixation, anangular tube of rigid or semi-rigid material capable of lying flat (asshown) is created, which tube may also be expanded into a rectangulartube shape (as shown in FIG. 7). Such expansion is accomplished by auser when a container is needed, by bending at fold lines 9 betweennon-folding side panels 23 and folding side panels 24. In FIG. 5, thetubular construction of the now folded blank 20 surrounds pouch 10, withpouch bottom fold 13 appearing between bottom flaps 22, and extendingapproximately up to bottom flap fold line 7. Top flaps 21 are attachedto the main body of the blank at fold lines 28, while bottom flaps 22are attached to the main body of the outer container at fold lines 29.The blank has been folded at fold lines 30, while additional fold lines9 (top fold line only is shown) allow expansion of the blank 20 into thetubular configuration.

[0099] In FIG. 6, the blank 20 is again shown, and again folded alongfold lines 30, with additional fold lines 9, and end tab 25 secured tonon-folding side panel 23 near blank mating edge 31 (not shown) as inFIG. 5. In FIG. 6, however, bottom flap 22 underneath pouch 10 has beenfolded at bottom flap fold line 7 over the bottom fold 13 of pouch 10,and secured to opposing bottom flap 22 on the upper side of thecontainer. By such folding and securing, a flexible bottom for thecontainer is created which allows expansion and contraction of thecontainer as desired.

[0100] In FIG. 7, the rigid blank 20 is again shown viewed from itsbottom, but in its expanded configuration, with bottom flaps 22 andbottom flap fold lines 29 nearest the viewer, and top flaps 21 and topflap fold lines 28 away from the viewer. One fold line 30 is againapparent, however fold lines 9 are, in the expanded configurationapparent as the lines of intersection between non-folding side panels 23and folding side panels 24. Pouch end edges 11 may are apparentextending beyond top flaps 21. However, pouch 10 is no longer apparentthrough the bottom of the container, as interior bottom flaps 22 havebeen manipulated from their fold down configuration to their expandedconfiguration. As interior bottom flaps 22 have been fastened togetheralong bottom flap attachment area 19 to create a flexible bottom, thebottom of the container is now closed, with pouch 10 on the interior,and exterior bottom flaps 22 remaining to be folded into position andlocked in place. In such position, and because of the previousattachment of pouch 10 to blank 20 along attachment areas 26 (nowshown), the pouch has followed the sidewalls 23 and 24 of the blank 20in its expansion, thereby also expanding pouch 10. The cut corners ofpouch 10 have largely withdrawn into the container in FIG. 7, therebysaving volume within the container and bulk when folding the remainingbottom flaps 22 into position over the bottom of the container formed bythe interior bottom flaps 22. However, as noted above, pouch 10 may alsobe formed without cutting corners 16, in which case the material formingsuch corners may be simply folded across the bottom formed by interiorbottom flaps 22. Such folding over the bottom of the container will alsogenerally result in folding the flaps of the folding sidewalls over theexposed bottom corners of the inner pouch, which normally project fromthe interior of the contain out between the folding sidewalls and thenow straightened flaps of the non-folding sidewalls. A user may continueexpansion by folding exterior bottom flaps 22 over the bottom of thecontainer, and locking the exterior bottom flaps 22 into slots formed ininterior bottom flaps 22, or by sealing the exterior bottom flaps inposition or together with tape or by other conventional means, a solidlyconstructed bottom for the container is formed which holds the containeropen, and ready to receive articles for transport or storage.

[0101] Referring to FIG. 8, the rigid container of the present inventionis again shown in perspective, from the top, the blank 20 again fullyfolded at fold lines 9 and expanded to straighten fold line 30 offolding side panels 24. Pouch 10 again appears in expanded configurationas it has expanded with the expansion of the container wider sidewalls23, and top flaps 21 and pouch opening 15 appear open for receivingobjects. In its expanded configuration, the blank 20 has been opened upby bending at its fold lines 7, and straightening sidewalls 24 at foldlines 30. The pouch 10 appearing in FIG. 2 has followed the side wallsof the outer container 20 in FIG. 7, both at the top and the bottom ofthe pouch 10. Accordingly, pouch top edges 11 are pulled open by theadhesive at the interior corners of the outer container applied at thepreferred areas 26, shown in FIG. 3, creating opening 15 in the pouch 10through which objects may be passed for placement within the pouch 10.

[0102] Referring now to FIG. 9, the process of manufacturing the presentinvention is shown in flow chart form. In FIG. 9, rigid or semi-rigidmaterial is selected to form a blank 100 of suitable characteristics,and a blank is prepared. In such material, fold lines or score lines arepressed or scored 101, and a blank of the desired size and shape is thencut 102 as set forth above to produce a blank with fold lines or scorelines in the correct positions. The blank may be cut 103 and thenpressed or scored 104 as set forth above to produce fold lines or scorelines at the correct positions in the material of the blank. However,the most usual method with operations of this kind, and the preferredmethod within the scope of the present invention, is to accomplish thecutting of the blank 102/103 simultaneously with the scoring or pressingof the blank 101/104, “cookie cutter” fashion, utilizing a singlecutting and stamping die in a single step. Whether the blank is cutbefore, after, or with the placement of fold lines or score lines,attachment means, generally an adhesive, may then be applied 105 topreferred attachment means areas 26, or additionally to preferredattachment means 27, or additionally to one entire surface of each ofthe non-folding side panels 23.

[0103] Before or after the above series of steps taken to prepare ablank, or before or after any such steps, a flexible, waterproof,air-tight, and insulated material is selected to form a pouch 120 ofsuitable characteristics, and a pouch is prepared. From such material, arectangle may be cut 121, and the rectangle folded 122. In thealternative, two squares or rectangles may be cut 123 having the samearea as the folded rectangle to produce a pouch having the same volume.Whether a single rectangle is cut 121 and folded 122 or two rectanglesare cut 123, the loose edges of the material so cut are matched 124, atleast approximately, for later sealing, or cutting and sealing. Once theedges of the material are matched 124, the manufacturer may elect tosimply seal the side edges 125 (or side and bottom edges in the case ofa pouch formed from two pieces of material), thereby creating a pouch 10with opening 15, and corners 16. In the alternative, the manufacturermay elect to cut the corners 126 of the pouch 10 after sealing, and sealthe cut edges where the corners were cut away 127, thereby creating thesame pouch but with shortened (or not) corners. The manufacturer may inthe alternative cut the edges and corners 128 of the materialsimultaneously 128 after matching edges 124, and seal the side edges andcut edges where the corners were cut away 129 if a pouch without cornersis desired.

[0104] Once a blank is prepared and a pouch is prepared using the abovemethod, the pouch is placed on the blank 150 in the correct position asset forth above, between fold lines 30, and the pouch is pressed intothe attachment means 151 of areas 26 (or so much attachment means as ispresent in areas 26, 27, and the remainder of non-folding side panel23). Once the pouch is securely affixed to the blank, the blank may thenbe folded 152 at side panel fold lines 30, so that end tab and matchingedge of the blank overlap, and end tab and the area at the end of theblank, near its matching edge may be fastened together 153, therebycreating an angular tubular arrangement of sidewalls. Once the tubulararrangement of sidewalls has been created, that longest bottom flaphaving an area for fastening 19, may then be folded 154 over the pouch10, and over the edge of opposing bottom flap 22, and the attachmentmeans of that area for fastening 19 used to fasten the first bottom flapto the opposing bottom flap 155.

What is claimed is:
 1. A water-resistant container, comprising: acontainer having a first folding sidewall and a second folding sidewall,the first and second folding sidewalls being opposing containersidewalls, the first and second folding sidewalls each having twoopposing edges creating widths, the first and second folding sidewallshaving fold lines approximately midway between their opposing edges, thefold lines running approximately from the top of each of the first andsecond folding sidewalls to the bottom of each of the first and secondfolding walls, the container having a first non-folding sidewall and asecond non-folding sidewall, the first and second non-folding sidewallsbeing opposing container walls, the first and second folding sidewallsaffixed at two of their edges to two edges of the first and secondnon-folding sidewalls to form a tubular section, the tubular sectionhaving a top end and a bottom end, the first end of the tubular sectionhaving a plurality of flaps attached thereto, the second end of thetubular section having a plurality of flaps attached thereto, the firstand second folding sidewalls and the first and second non-foldingsidewalls having interior surfaces facing the interior of the tubularsection and exterior surfaces facing the exterior of the tubularsection, the intersection of the edges of the first and second foldingsidewalls with the edges of the first and second non-folding sidewallscreating corners of the container, the first and second non-foldingsidewalls having areas near the corners of the container, on theinterior surfaces of the non-folding sidewalls, for attachment means,and a pouch having an interior, a first exterior side, a second exteriorside, a bottom edge, a right edge, a left edge, a plurality of top edgesforming a top opening, the pouch being formed from a flexible andwater-resistant material, the pouch residing within the tubular sectionof the container, the right edge of the pouch residing near the foldline of the first folding sidewall and the left edge of the pouchresiding near the fold line of the second folding sidewall, the topedges of the pouch extending from the top end of the tubular section atleast a distance equal to one-half the width of the folding sidewalls,the bottom edge of the pouch extending from the bottom end of thetubular section at least a distance equal to one-half the width of thefolding sidewalls.
 2. The water-resistant container of claim 1, furthercomprising means for attaching the first exterior side of the pouch tothe attachment areas of the first non-folding sidewall, and means forattaching the second exterior side of the pouch to the attachment areasof the second non-folding sidewall.
 3. The water-resistant container ofclaim 2, wherein the flexible and water-resistant material is alsothermally insulative.
 4. The water-resistant container of claim 3,wherein the flexible, water-resistant, and thermally insulative materialcomprises at least one layer of material having bubbles of gas entrappedtherein.
 5. The water-resistant container of claim 4, wherein theflexible, water-resistant, and thermally insulative material furthercomprises at least one layer of reflective material.
 6. Thewater-resistant container of claim 5, wherein the means for attachingthe pouch to the interior surfaces of the walls of the outer containercomprises an adhesive.
 7. The water-resistant container of claim 6,wherein the means for attaching the pouch to the interior surfaces ofthe walls of the outer container comprises a releasable adhesive.
 8. Thewater-resistant container of claim 7, further comprising means forsealing the pouch top opening.
 9. The water-resistant container of claim1, wherein the flexible and water-resistant material is also thermallyinsulative.
 10. The water-resistant container of claim 9, wherein theflexible, water-resistant, and thermally insulative material comprisesat least one layer of material having bubbles of gas entrapped therein.11. The water-resistant container of claim 10, wherein the flexible,water-resistant, and thermally insulative material further comprises atleast one layer of reflective material.
 12. A thermally insulativecontainer, comprising: a container having a first folding sidewall and asecond folding sidewall, the first and second folding sidewalls beingopposing container sidewalls, the first and second folding sidewallseach having two opposing edges creating widths, the first and secondfolding sidewalls having fold lines approximately midway between theiropposing edges, the fold lines running approximately from the top ofeach of the first and second folding sidewalls to the bottom of each ofthe first and second folding walls, the container having a firstnon-folding sidewall and a second non-folding sidewall, the first andsecond non-folding sidewalls being opposing container walls, the firstand second folding sidewalls affixed at two of their edges to two edgesof the first and second non-folding sidewalls to form a tubular section,the tubular section having a top end and a bottom end, the first end ofthe tubular section having a plurality of flaps attached thereto, thesecond end of the tubular section having a plurality of flaps attachedthereto, the first and second folding sidewalls and the first and secondnon-folding sidewalls having interior surfaces facing the interior ofthe tubular section and exterior surfaces facing the exterior of thetubular section, the intersection of the edges of the first and secondfolding sidewalls with the edges of the first and second non-foldingsidewalls creating corners of the container, the first and secondnon-folding sidewalls having areas near the corners of the container, onthe interior surfaces of the non-folding sidewalls, for attachmentmeans, and a pouch having an interior, a first exterior side, a secondexterior side, a bottom edge, a right edge, a left edge, a plurality oftop edges forming a top opening, the pouch being formed from a flexibleand thermally insulative material, the pouch residing within the tubularsection of the container, the right edge of the pouch residing near thefold line of the first folding sidewall and the left edge of the pouchresiding near the fold line of the second folding sidewall, the topedges of the pouch extending from the top end of the tubular section atleast a distance equal to one-half the width of the folding sidewalls,the bottom edge of the pouch extending from the bottom end of thetubular section at least a distance equal to one-half the width of thefolding sidewalls.
 13. The water-resistant container of claim 12,further comprising means for attaching the first exterior side of thepouch to the attachment areas of the first non-folding sidewall, andmeans for attaching the second exterior side of the pouch to theattachment areas of the second non-folding sidewall.
 14. The thermallyinsulative container of claim 13, wherein the flexible andwater-resistant material is also water tight.
 15. The thermallyinsulative container of claim 14, wherein the flexible, water-resistant,and thermally insulative material comprises at least one layer ofmaterial having bubbles of gas entrapped therein.
 16. The thermallyinsulative container of claim 15, wherein the flexible, water-resistant,and thermally insulative material further comprises at least one layerof reflective material.
 17. The thermally insulative container of claim16, wherein the means for attaching the pouch to the interior surfacesof the walls of the outer container comprises an adhesive.
 18. Thethermally insulative container of claim 17, wherein the means forattaching the pouch to the interior surfaces of the walls of the outercontainer comprises a releasable adhesive.
 19. The thermally insulativecontainer of claim 18, further comprising means for sealing the pouchtop opening.
 20. The thermally insulative container of claim 12, whereinthe flexible and water-resistant material is also thermally insulative.21. The thermally insulative container of claim 13, wherein theflexible, water-resistant, and thermally insulative material comprisesat least one layer of material having bubbles of gas entrapped therein.22. The thermally insulative container of claim 14, wherein theflexible, water-resistant, and thermally insulative material furthercomprises at least one layer of reflective material.
 23. A method ofmaking a water-tight container comprising the steps of: taking a flatblank for a tubular assembly, the blank having, in order, a first sidepanel, a second side panel, a third side panel, and a fourth side panel,the blank having a plurality of fold lines between the first, second,third, and fourth side panels, the blank having bottom flaps along itsbottom edge for forming a bottom closure, and top flaps along its topedge for forming a top closure, taking a length of plastic sheetmaterial in lay flat tubular form, the plastic sheet material having afirst side and a second side, and a first edge and a second edge, theplastic sheet material being sealed at one end and open at the otherend, the plastic sheet material having a lay flat width approximatelyequal to one-half the combined width of the side panels of the flatblank, securing a first attachment means to the second side panel of theblank, securing a second attachment means to the fourth side panel ofthe blank, laying the plastic sheet material on the flat blank with thewidth of the plastic sheet material extending across the width of thesecond side panel, the plastic sheet material also extending acrossapproximately one-half the width of the first side panel and acrossapproximately one-half the width of the third side, thereby attachingthe plastic sheet material to the first attachment means of the blank,the sealed end of the plastic sheet material positioned generally nearthe ends of the bottom flaps of the blank, the open end of the plasticsheet material positioned generally near the ends of the top flaps ofthe blank, thereby attaching the first side of the plastic sheetmaterial to the first attachment means of the blank in such position,folding approximately one-half the width of the first side panel acrossthe plastic sheet material, folding approximately one-half the width ofthe third side panel, and the fourth panel, across the plastic sheetmaterial, so that a first free edge of the folded first side panelapproximately meets a second free edge of the fourth side panel, therebyattaching the second side of the plastic sheet material to the secondattachment means, and securing the first free edge of the folded firstside panel to the second free edge of the fourth side panel, therebyforming a tubular folded container assembly with the plastic sheetmaterial adhered to the inside of the tubular assembly along the firstand second attachment means.
 24. method of making a water-tightcontainer of claim 23, further comprising the steps of expanding thetubular folded container assembly to create a volume therewithin, andthen folding the bottom flaps to form a bottom for the expandedcontainer assembly.
 25. The method of making a water-tight container ofclaim 24, further comprising the step of closing the open end of theplastic sheet material to form a water-tight pouch.
 26. A method ofmaking a water-tight container comprising the steps of: taking a flatblank for a tubular assembly, the blank having, in order, a first sidepanel, a second side panel, a third side panel, and a fourth side panel,the blank having a plurality of fold lines between the first, second,third, and fourth side panels, the blank having bottom flaps along itsbottom edge for forming a bottom closure, and top flaps along its topedge for forming a top closure, taking a length of plastic sheetmaterial in lay flat tubular form, the plastic sheet material having afirst side and a second side, and a first edge and a second edge, theplastic sheet material being sealed at one end and open at the otherend, the plastic sheet material having a lay flat width approximatelyequal to one-half the combined width of the side panels of the flatblank, laying the plastic sheet material on the flat blank with thewidth of the plastic sheet material extending across the width of thesecond side panel, the plastic sheet material also extending acrossapproximately one-half the width of the first side panel and acrossapproximately one-half the width of the third side, the sealed end ofthe plastic sheet material positioned generally near the ends of thebottom flaps of the blank, the open end of the plastic sheet materialpositioned generally near the ends of the top flaps of the blank,folding approximately one-half the width of the first side panel acrossthe plastic sheet material, folding approximately one-half the width ofthe third side panel, and the fourth panel, across the plastic sheetmaterial, so that a first free edge of the folded first side panelapproximately meets a second free edge of the fourth side panel, andsecuring the first free edge of the folded first side panel to thesecond free edge of the fourth side panel, thereby forming a tubularfolded container assembly with the plastic sheet material residingwithin the tubular assembly.
 27. method of making a water-tightcontainer of claim 26, further comprising the steps of expanding thetubular folded container assembly to create a volume therewithin, andthen folding the bottom flaps to form a bottom for the expandedcontainer assembly.
 28. The method of making a water-tight container ofclaim 27, further comprising the step of closing the open end of theplastic sheet material to form a water-tight pouch.